Multi-cleat  industrial bin

ABSTRACT

The multiple cleat bin of the present invention includes a base, a front wall, two opposing sidewalls, and a substantially vertical rear wall having an upper rim. The rear wall includes a cleat near the upper rim of the rear wall and a second cleat formed at the base of the rear wall. A third cleat formed in the rear wall may also be included. A fourth cleat formed in the rear wall may also be included. Preferably, a forewall and kick out wall are included to form a stacking space such that a second may be placed within bin for increased packing density for shipping or storage. The additional cleats provide additional strength for bins manufactured of more economical or recycled polymers that tend to be softer or less rigid. The use of multiple cleats allows for improved strength and flexibility in use. The bin may also include multi-element structural trusses at the front wall, right sidewall, rear wall and left sidewall are integrally formed such that they form a single structural element that encircles the upper edge of bin.

FIELD OF THE INVENTION

The present invention relates to storage and transport systems and more particularly to bin system for use in storing parts for use in assembly. The multiple cleat bin of the present invention includes a base, a front wall, two opposing sidewalls, and a substantially vertical rear wall having an upper rim. The rear wall includes a cleat near the upper rim of the rear wall and a second cleat formed at the base of the rear wall. A third cleat formed in the rear wall may also be included. A fourth cleat formed in the rear wall may also be included. Preferably, a forewall and kick out wall are included to form a stacking space such that a second may be placed within bin for increased packing density for shipping or storage. The additional cleats provide additional strength for bins using less costly materials that may not have the strength and rigidity of currently used materials.

BACKGROUND

Bin systems are often used in industrial sites to aid in storing and sorting a number of small parts. Typically, the bins are open topped and hung horizontally from a single cleat formed on the back wall of the bin when the bin is molded or manufactured.

SUMMARY

In accordance with embodiments of the present invention, a bin for industrial applications having a plurality of cleats on the back wall is provided. The bin may also include multi-element structural trusses at the front wall, right sidewall, rear wall and left sidewall are integrally formed such that they form a single structural element that encircles the upper edge of bin. The bin may be thermoformed, injection molded, blow molded, or rotocasted and may be formed of any suitable polymer such as polypropylene, polyethylene, polycarbonate, SMMA and HIPS or other injection grade polymers.

BRIEF DESCRIPTION OF THE DRAWINGS

A more complete appreciation of the invention and the many embodiments thereof will be readily obtained as the same becomes better understood by reference to the following detailed description when considered in connection with the accompanying drawings, wherein:

FIG. 1A illustrates a perspective view of a four cleat bin in accordance with the present invention;

FIG. 1B illustrates a side plan view of a four cleat bin in accordance with the present invention;

FIG. 1C illustrates a rear plan view of a four cleat bin in accordance with the present invention;

FIG. 1D illustrates a bottom plan view of a four cleat bin in accordance with the present invention;

FIG. 2 shows a side plan view, in detail, of a top cleat in a multicleat bin of the present invention.

FIG. 3 shows a front plan view of a multicleat bin of the present invention.

FIG. 4 shows a top plan view of a multicleat bin of the present invention.

FIG. 5A illustrates a perspective view of a three cleat bin in accordance with the present invention;

FIG. 5B illustrates a side plan view of a three cleat bin in accordance with the present invention;

FIG. 5C illustrates a rear plan view of a three cleat bin in accordance with the present invention;

FIG. 6A illustrates a perspective view of a two cleat bin in accordance with the present invention;

FIG. 6B illustrates a side plan view of a two cleat bin in accordance with the present invention;

FIG. 6C illustrates a rear plan view of a two cleat bin in accordance with the present invention;

DETAILED DESCRIPTION

The present invention will now be described with occasional reference to the specific embodiments of the invention. This invention may, however, be embodied in different forms and should not be construed as limited to the embodiments set forth herein. Rather, these embodiments are provided so that this disclosure will be thorough and complete, and will fully convey the scope of the invention to those skilled in the art.

Unless otherwise defined, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this invention belongs. The terminology used in the description of the invention herein is for describing particular embodiments only and is not intended to be limiting of the invention. As used in the description of the invention and the appended claims, the singular forms “a,” “an,” and “the” are intended to include the plural forms as well, unless the context clearly indicates otherwise.

Unless otherwise indicated, all numbers expressing quantities of ingredients, properties such as molecular weight, reaction conditions, and so forth as used in the specification and claims are to be understood as being modified in all instances by the term “about.” Accordingly, unless otherwise indicated, the numerical properties set forth in the specification and claims are approximations that may vary depending on the desired properties sought to be obtained in embodiments of the present invention. Notwithstanding that the numerical ranges and parameters setting forth the broad scope of the invention are approximations, the numerical values set forth in the specific examples are reported as precisely as possible. Any numerical values, however, inherently contain certain errors necessarily resulting from error found in their respective measurements.

The perspective view of a four cleat bin 10 of the present invention is shown in FIG. 1A. Bin 10 includes front wall 12, right sidewall 14, rear wall 16 and left sidewall 18 and bin floor 20. Front wall 12 includes an upper rim 12 a, hand hold 28, label holder 26. Handhold 28 is angled away from front wall 12 forming hollow 24, into which the fingers may be inserted to pull bin 10 toward the user. Handhold 28 includes a rearward extension 22. Right sidewall 14 includes upper rim 14 a, kick out wall 14 b, forewall 14 c, base rail 14 d, and footer 14 e. Upper rim 14 a includes a depression 14 f and inner flat 14 g, which receive footer 14 e and base rail 14 d of a second bin 10 stacked above the first bin 10. Rear wall 16 includes top rail 16 a that includes top cleat 30, central cleats 32, 34 are integrally formed with the rear wall, and base cleat 36 is formed at the lower edge of rear wall 16 and notched out of sidewalls 14, 18. Left sidewall 18 includes upper rim 18 a, kick out wall 18 b, forewall 18 c, a base rail (not shown) and a footer (not shown) the upper rim 18 a includes a depression 18 f and inner flat 18 g, which receive the footer and base rail of a second bin 10 stacked above the first bin 10.

The side view of a four cleat bin 10 of the present invention is shown in FIG. 1B. The side view of bin 10 shows front wall 12, right sidewall 14, and rear wall 16. Front wall 12 includes an upper rim 12 a, hand hold 28, label holder 26. Handhold 28 is angled away from front wall 12 forming hollow 24, into which the fingers may be inserted to pull bin 10 toward the user. Handhold 28 includes a rearward extension 22 that reinforces the handhold when in use. Right sidewall 14 includes upper rim 14 a, kick out wall 14 b, forewall 14 c, base rail 14 d, and footer 14 e. Rear wall 16 includes top rail 16 a that includes top cleat 30, central cleats 32, 34 are integrally formed with the rear wall, and base cleat 36 is formed at the lower edge of rear wall 16 and notched out of sidewalls 14, 18. Kick out wall 14 b is angled forward by between 5° and 30°, sidewall 14 is angled outwardly from vertical by between 2° and 10°, and forewall 14 c is displaced outwardly to forma stacking space such that a second bin 10 may be placed within the lower bin for increased packing density for shipping or storage.

The rear wall 16 of a four cleat bin 10 of the present is shown in FIG. 1C. Rear wall 16 includes top rail 16 a that includes top cleat 30, central cleats 32, 34 in the center of the rear wall, and base cleat 36 at the lower edge of rear wall 16. Handhold 28 includes a rearward extension 22 on the right and left sides. Right sidewall 14 includes upper rim 14 a, kick out wall 14 b, a forewall 14 c, base rail 14 d, and footer 14 e (not shown). Left sidewall 18 includes upper rim (not shown), kick out wall 18 b, forewall 18 c, a base rail 18 d, and a footer (not shown). When placed on a louvered panel or rack system, bin 10 engages four rows of louvers with the cleats 30, 32, 34, 36 such that bin 10 is substantially horizontal. Bin 10 may also be placed on a shelf and pulled forward on the shelf using handhold 28.

The bottom view of a multicleat bin of the present invention is shown in FIG. 1D. Bin 10 includes front wall 12, right sidewall 14, rear wall 16 and left sidewall 18 and bin floor 20. Front wall 12 includes an upper rim 12 a, handhold 28, label holder 26. Handhold 28 is angled away from front wall 12 and includes a rearward extension 22. Positioned between front wall 12 and handhold 28 are a number of reinforcing beams 12 b, which are formed in the molding process and extend from front wall 12 to handhold 28. Beams 12 b, in combination with front wall 12 and handhold form a multi-element structural truss. Right sidewall 14 includes upper rim 14 a, kick out wall 14 b, forewall 14 c, base rail 14 d, and footer 14 e. Upper rim 14 a includes a depression 14 f and inner flat 14 g. Reinforcing beams 14 i, which are formed in the molding process span the inner flat 14 g and extend from sidewall 14 to rim 14 a. Reinforcing beams 14 h, also formed in the molding process span the upper rim 14 a. The beams 14 i, 14 h in combination with sidewall 14, upper rim 14 a and inner flat 14 g form a multi-element structural truss.

Rear wall 16 includes top rail 16 a that includes top cleat 30, central cleats 32, 34 are integrally formed with the rear wall, and base cleat 36 is formed at the lower edge of rear wall 16 and notched out of sidewalls 14, 18. Reinforcing beams 30 a, 30 b, formed during the molding process extend from sidewall 16 to the top cleat 30. Beams 30 a, 30 b in combination with sidewall 16 and top cleat 30 form a multi-element structural truss.

Left sidewall 18 includes upper rim 18 a, kick out wall 18 b, forewall 18 c, base rail 18 d, and footer 18 e. Upper rim 18 a includes a depression 18 f and inner flat 18 g. Reinforcing beams 18 i, which are formed in the molding process span the inner flat 18 g and extend from sidewall 18 to rim 18 a. Reinforcing beams 18 h, also formed in the molding process span the upper rim 18 a. The beams 18 i, 18 g in combination with sidewall 18, upper rim 18 a and inner flat 18 g form a multi-element structural truss.

Rearward extensions 22 link the front wall 12 to sidewalls 14, 18. The rearward extension 22 is formed with a diagonal beam 12 c as well as perpendicular beam 22 a. On right sidewall 14 the forewall 14 c is linked to the rearward extension 22 by and top rail 14 a by beams 12 a, 12 c to form a multi-element structural truss. On left sidewall 18 the forewall 18 c is linked to the rearward extension 22 by and top rail 18 a by beams 12 a, 12 c to form a multi-element structural truss.

Base 20 may include longitudinal reinforcements 20 a, latitudinal reinforcements 20 b and/or curved reinforcements 20. Reinforcements 20 a, 20 b, 20 c serve to reinforce the base of the bin in high load situations.

The multi-element structural trusses at the front wall 12, rearward extensions 22, right sidewall 14, rear wall 16 and left sidewall 18 are integrally formed such that they form a single structural element that encircles the upper edge of bin 10 provide improved strength and rigidity in high load applications.

A detailed side view of a cleat suitable for use with bin of the present invention is shown in FIG. 2. Cleat 30 includes projection 30 a that descends from rear wall 16. The projection includes a curved transition 42. A louver of a louvered rack or a rail of a rail system fits into cleat 30 and contacts the radius 42 and the inner surface of projection 30 a. Radius 42 and projection 30 a support a portion of the weight of bin 10. The radius 42 and projection 30 a also bear the torque generated by a loaded bin 10 when hung.

The front view of bin 10 of the present invention is shown in FIG. 3. Front wall 12 includes an upper rim 12 a, hand hold 28, label holder and rearward extension 22. Right sidewall 14 includes upper rim 14 a, kick out wall 14 b, forewall 14 c, base rail 14 d, and footer 14 e. Upper rim 14 a includes a depression 14 f and inner flat 14 g, which receive footer (not shown) and base rail 14 d of a second bin 10 stacked above the first bin 10. Rear wall 16 includes top rail 16 a to form cleat 30, a central cleat 32 is also shown. Opposed rails 40 formed on rear wall 16 form an insert for a longitudinal bin separator. Left sidewall 18 includes upper rim 18 a, kick out wall 18 b, forewall 18 c, a base rail 18 d and footer (not shown) the upper rim 18 a includes a depression 18 f and inner flat 18 g, which receive the footer and base rail of a second bin 10 stacked above the first bin 10.

The top view of bin 10 of the present invention is shown in FIG. 4. Front wall 12 includes an upper rim 12 a, label holder 26, opposed rails 46 a, 46 b and opposed rails 44 a, 44 b forming a retainers for a longitudinal bin separator. Right sidewall 14 includes upper rim 14 a, kick out wall 14 b, forewall 14 c. Upper rim 14 a includes a depression 14 f and inner flat 14 g, which receive footer (not shown) and base rail (not shown) of a second bin 10 stacked above the first bin 10. An optional second depression 14 h, which may include an orifice 14 i, receives a tab to lock stacked bins together. Rear wall 16 includes top rail 16 a. Rear wall 16 may also include opposed rails 40 a, 40 b and 42 a, 42 b forming retainers for a longitudinal bin separator. Left sidewall 18 includes upper rim 18 a, kick out wall 18 b, forewall 18 c. Upper rim 18 a includes a depression 18 f and inner flat 18 g, which receive footer (not shown) and base rail (not shown) of a second bin 10 stacked above the first bin 10. A second depression 18 h, which may include an orifice 18 i, receives a tab to lock stacked bins together.

The perspective view of a three cleat bin 110 of the present invention is shown in FIG. 5A. Bin 110 includes front wall 112, right sidewall 114, rear wall 116, left sidewall 118, and bin floor 120. Front wall 112 includes an upper rim 112 a, hand hold 128, label holder 126. Handhold 128 is angled away from front wall 112 forming hollow 124, into which the fingers may be inserted to pull bin 110 toward the user. Handhold 128 includes a rearward extension 122. Right sidewall 114 includes upper rim 114 a, kick out wall 114 b, forewall 114 c, base rail 114 d, and footer 114 e. Upper rim 114 a includes a depression 114 f and inner flat 114 g, which receive footer 114 e and base rail 114 d of a second bin 110 stacked above the first bin 110. Rear wall 116 includes top rail 116 a that includes top cleat 130, central cleat 132 is formed with rear wall 116, and base cleat 136 is formed at the lower edge of rear wall 116 and notched out of sidewalls 114, 118. Left sidewall 118 includes upper rim 118 a, kick out wall 118 b, forewall 118 c, a base rail (not shown) and a footer (not shown) the upper rim 118 a includes a depression 118 f and inner flat 118 g, which receive the footer and base rail of a second bin 110 stacked above the first bin 110.

The side view of a three cleat bin 110 of the present invention is shown in FIG. 5B. The side view of bin 110 shows front wall 112, right sidewall 114, and rear wall 116. Front wall 112 includes an upper rim 112 a, hand hold 128, label holder 126. Handhold 128 is angled away from front wall 112 forming hollow 124, into which the fingers may be inserted to pull bin 110 toward the user. Handhold 128 includes a rearward extension 122 that reinforces the handhold when in use. Right sidewall 114 includes upper rim 114 a, kick out wall 114 b, forewall 114 c, base rail 114 d, and footer 114 e. Rear wall 116 includes top rail 116 a that includes top cleat 130, central cleat 132, and base cleat 136 is formed at the lower edge of rear wall 116 and notched out of sidewalls 114, 118. Kick out wall 114 b is angled forward by between 5° and 30°, sidewall 114 is angled outwardly from vertical by between 2° and 10°, and forewall 114 c is displaced outwardly to form a stacking space such that a second bin 110 may be placed within the lower bin for increased packing density for shipping or storage.

The rear wall 116 of bin 110 of the present is shown in FIG. 5C. Rear wall 116 includes top rail 116 a that includes top cleat 130, central cleat 132 in the center of the rear wall, and base cleat 136 at the lower edge of rear wall 116. Handhold 128 includes rearward extensions 122 on the right and left sides. Right sidewall 114 includes upper rim 114 a, kick out wall 114 b, a forewall 114 c, base rail 114 d, and footer 114 e (not shown). Left sidewall 118 includes upper rim (not shown), kick out wall 118 b, forewall 118 c, a base rail 118 d, and a footer 118 (not shown). When placed on a louvered panel or rail system, bin 110 engages three rows of louvers with cleats 130, 132, 136 such that bin 110 is substantially horizontal. Bin 110 may also be placed on a shelf and pulled forward on the shelf using handhold 128.

The perspective view of a two cleat bin 210 of the present invention is shown in FIG. 6A. Bin 210 includes front wall 212, right sidewall 214, rear wall 216 and left sidewall 218 and bin floor 220. Front wall 212 includes an upper rim 212 a, hand hold 228, label holder 226. Handhold 228 is angled away from front wall 212 forming hollow 224, into which the fingers may be inserted to pull bin 210 toward the user. Hand hold 228 includes a rearward extension 222. Right sidewall 214 includes upper rim 214 a, kick out wall 214 b, forewall 214 c, base rail 214 d, and footer 214 e. Upper rim 214 a includes a depression 214 f and inner flat 214 g, which receive footer 214 e and base rail 214 d of a second bin 210 stacked above the first bin 210. Rear wall 216 includes top rail 216 a that includes top cleat 230, and base cleat 236 is formed at the lower edge of rear wall 216 and notched out of sidewalls 214, 218. Left sidewall 218 includes upper rim 218 a, kick out wall 218 b, forewall 218 c, a base rail (not shown) and a footer (not shown) the upper rim 218 a includes a depression 218 f and inner flat 218 g, which receive the footer and base rail of a second bin 210 stacked above the first bin 210.

The side view of a two cleat bin 210 of the present invention is shown in FIG. 6B. The side view of bin 210 shows front wall 212, right sidewall 214, and rear wall 216. Front wall 212 includes an upper rim 212 a, hand hold 228, label holder 226. Handhold 228 is angled away from front wall 212 forming hollow 224, into which the fingers may be inserted to pull bin 210 toward the user. Hand hold 228 includes a rearward extension 222 that reinforces the hand hold when in use. Right sidewall 214 includes upper rim 214 a, kick out wall 214 b, forewall 214 c, base rail 214 d, and footer 214 e. Rear wall 216 includes top rail 216 a that includes top cleat 230, and base cleat 236 is formed at the lower edge of rear wall 216 and notched out of sidewalls 214, 218. Kick out wall 214 b is angled forward by between 5° and 30°, sidewall 214 is angled outwardly from vertical by between 2° and 10°, and forewall 214 c is displaced outwardly to form a stacking space such that a second bin 210 may be placed within the lower bin for increased packing density for shipping or storage.

The rear wall 216 of a two cleat bin 210 of the present is shown in FIG. 6C. Rear wall 216 includes top rail 216 a that includes top cleat 230, and base cleat 236 at the lower edge of rear wall 216. Handhold 228 includes a rearward extension 222 on the right and left sides. Right sidewall 214 includes upper rim 214 a, kick out wall 214 b, a forewall 214 c, base rail 214 d, and footer 214 e (not shown). Left sidewall 218 includes upper rim (not shown), kick out wall 218 b, forewall 218 c, a base rail 218 d, and a footer (not shown). When placed on a louvered panel or rack system, bin 210 engages two louvers with the cleats 230, 236 such that bin 210 is substantially horizontal. Bin 210 may also be placed on a shelf and pulled forward on the shelf using handhold 228.

The bin of the present invention may be formed by any suitable method including thermoforming, injection molding, blow molding, and rotocasting. The bin and dividers may be formed of any suitable material, such as: polypropylene, polyethylene, polycarbonate, SMMA (styrene methyl methacrylate, acrylic blend), or HIPS high impact polystyrene or other such materials commonly used in the manufacturing of polymeric parts and/or parts made by common forming techniques.

The present invention should not be considered limited to the specific examples described herein, but rather should be understood to cover all aspects of the invention. Various modifications, equivalent processes, as well as numerous structures and devices to which the present invention may be applicable will be readily apparent to those of skill in the art. Those skilled in the art will understand that various changes may be made without departing from the scope of the invention, which is not to be considered limited to what is described in the specification. 

What is claimed is:
 1. A bin having multiple cleats, comprising: a base, a front wall, two opposing sidewalls, and a rear wall having an upper rim, a midsection and a base; a first cleat proximate the upper rim of the rear wall; and a second cleat formed in the rear wall proximate to the base.
 2. The bin of claim 1, further comprising: a third cleat formed in the midsection of the rear wall beneath the first cleat.
 3. The bin of claim 1, further comprising: a third cleat formed in the midsection of the rear wall beneath the first cleat; and a fourth cleat formed in the midsection of the rear wall beneath the third cleat
 4. The bin of claim 1, wherein: the bin hangs substantially horizontally from a vertical louvered rack.
 5. The bin of claim 1, further comprising: a handhold attached to the front wall.
 6. The bin of claim 1, further comprising: at least one footer on each sidewall.
 7. The bin of claim 1, further comprising: multi-element structural trusses at the front wall, right sidewall, rear wall and left sidewall are integrally formed such that they form a single structural element that encircles the upper edge of bin.
 8. A bin having multiple cleats, comprising: a base, a front wall, two opposing sidewalls, and a substantially vertical rear wall having an upper rim, a midsection and a base; each sidewall including an upper rim, a kick out wall, and a forewall; a first cleat proximate the upper rim of the rear wall; a second cleat formed in the rear wall proximate to the base; and a third cleat formed in the midsection of the rear wall beneath the first cleat.
 9. The bin of claim 8, further comprising: a depression formed in the upper rim of the sidewalls and inner flat formed in the upper rim of the sidewalls.
 10. The bin of claim 8, further comprising: a fourth cleat formed in the midsection of the rear wall beneath the third cleat.
 11. The bin of claim 8, wherein the front wall is at an obtuse angle to the base,
 12. The bin of claim 8, wherein the opposing sidewalls are formed at an obtuse angle to the base.
 13. The bin of claim 8, wherein the rear wall is substantially vertical with respect to the base.
 14. The bin of claim 8, wherein the kick out wall is angled forward by between 5° and 30°.
 15. The bin of claim 8, wherein the sidewall formed at an obtuse angle with respect to the base.
 16. The bin of claim 8, wherein the forewall and kick out wall form a stacking space such that a second may be placed within bin for increased packing density for shipping or storage.
 17. The bin of claim 8, further comprising: multi-element structural trusses at the front wall, right sidewall, rear wall and left sidewall are integrally formed such that they form a single structural element that encircles the upper edge of bin.
 18. A bin having multiple cleats, comprising: a base, a front wall, two opposing sidewalls, and a substantially vertical rear wall having an upper rim, a midsection and a base; each sidewall including an upper rim, a kick out wall, and a forewall; a first cleat proximate the upper rim of the rear wall; a second cleat formed in the rear wall proximate to the base; a third cleat formed in the midsection of the rear wall beneath the first cleat; and a fourth cleat formed in the midsection of the rear wall beneath the third cleat.
 19. The bin of claim 18, further comprising: a depression formed in the upper rim of the sidewalls and inner flat formed in the upper rim of the sidewalls.
 20. The bin of claim 18, wherein the front wall and opposing sidewalls are formed at an obtuse angle to the base,
 21. The bin of claim 18, wherein the kick out wall is angled forward.
 22. The bin of claim 18, wherein the forewall and kick out wall form a stacking space such that a second may be placed within bin for increased packing density for shipping or storage.
 23. The bin of claim 18, further comprising: multi-element structural trusses at the front wall, right sidewall, rear wall and left sidewall are integrally formed such that they form a single structural element that encircles the upper edge of bin. 